This is an archived copy of the 2013 Catalog. To access the most recent version of the catalog, please visit http://catalog.jccc.edu.

Railroad Operations- Welding Option, A.A.S.

Overview
Courses

Maintenance of way welding involves maintenance and repair of rail and track components. The final phase of this program consists of course work provided in cooperation with the National Academy of Railroad Sciences. Selective admission to the program is based on various criteria. Interested students should meet with a JCCC counselor as early as possible.

For information visit the National Academy of Railroad Sciences. Hover your cursor over the "New Careers" tab and choose from the list.

(Major Code 2850; State CIP Code 49.0208)

First Semester

CPCA 105	Introduction to Personal Computers: Windows	1
ENGL 121	Composition I*	3
MATH 130	Technical Mathematics I*	3
PHIL 124	Logic and Critical Thinking	3
RRT 120	History of Railroading	3
Total Hours		13

Second Semester

ENGL 123	Technical Writing I*	3
INDT 125	Industrial Safety/OSHA 30	3
PHYS 133	Applied Physics*	5
RRT 121	Railroad Technical Careers	3
Health and/or Physical Education Elective ^{^}		1
Total Hours		15

^	Health and/or Physical Education Elective

Third Semester

Technical/Related Elective (see below)		6
ECON 132	Survey of Economics	3
or ECON 230	Economics I
RRT 150	Railroad Operations	3
RRT 165	Railroad Safety, Quality and Environment	3
SPD 125	Personal Communication	3
Total Hours		18

Fourth Semester

Technical/Related Elective (see below)		3
RRIT 122	Elements of Welding*	3
RRIT 123	Basic Welding*	3
RRIT 132	Thermite Welding*	3
RRIT 136	Rail and Switch Point Repair Welding*	3
RRIT 145	Frog Welding*	3
Total Hours		18

Technical/Related Electives

AUTO 125	Introduction to Automotive Shop Practices	3
AUTO 165	Automotive Engine Repair*	4
CET 105	Construction Methods	3
CET 129	Construction Management	3
DRAF 123	Interpreting Machine Drawings*	2
DRAF 129	Interpreting Architectural Drawings	2
HVAC 123	Electromechanical Systems	4
MFAB 124	Introduction to Welding	3
MFAB 128	Basic Machine Tool Technology	3
MFAB 140	Maintenance Repair Welding*	3
MFAB 180	Blueprint and Symbols Reading for Welders	2
MFAB 240	Metallurgy	2
RRIT 137	Structural Welding SMAW*	3
RRIT 138	Structural Welding FCAW*	3
RRIT 140	Structural Quality SMAW*	3
RRIT 141	Structural Quality GMAW*	3
RRIT 142	Structural Pile Welding*	3
RRIT 160	Mechanical Basic Welding*	3
RRIT 162	Mechanical Welding Structural Stick*	3
RRIT 164	Mechanical Welding Structural Wire*	3
RRIT 166	Mechanical Welding Air Brake Pipe* (Prerequisite:Approval of Burlington Northern Santa Fe (BNSF) Training Director)	3
RRIT 168	Mechanical Welding Sheet Metal* (Prerequisite:Approval of Burlington Northern Santa Fe (BNSF) Training Director)	3

Total Program Hours: 64

Courses

RRIT 122 Elements of Welding (3 Hours)

Prerequisites: Approval of the BNSF manager of track and roadway maintenance training and the JCCC department approval

Upon successful completion of this course, the student should be able to cut and weld using oxyfuel (OFC) and shielded metal arc welding (SMAW). OFC will cover straight-line cutting, beveling, piercing and gouging. The SMAW portion will cover flat position and will be limited to fillet welds. The student should be able to discuss electrical safety in shielded metal arc welding (SMAW), handle welding cables properly, understand eye hazards, list safe clothing requirements and discuss environmental safety. This knowledge will be evidenced by achieving the specified score on the unit test. 2 hrs. lecture, 3 hrs. lab/wk.

RRIT 123 Basic Welding (3 Hours)

Prerequisites: RRIT 122 or approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Upon successful completion of this course, the student should be able to properly use oxy-fuel cutting (OFC), shielded metal arc welding (SMAW) and air carbon arc cutting (CAC-A) equipment. The SMAW portion of the course will concentrate on 1G and 2F welds with bend tests being performed on selected weldments. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 132 Thermite Welding (3 Hours)

Prerequisites: Approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Upon successful completion of this course, the student should be able to produce in a safe manner high-quality, sound thermite welds on standard rail and mismatched rail. This course is intended for people who are employed in the railroad industry. It will include specific in-depth industrial training. Students will be required to make various rail alignments and to grind various new and worn rails. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 136 Rail and Switch Point Repair Welding (3 Hours)

Prerequisites: RRIT 123 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Upon successful completion of this course, the student should be able to identify and/or produce in a safe manner high-quality welding repairs and correct welding techniques to railroad track components to include maintenance, grinding, welding and repairs of switches, track rail ends, track wheel burns, battered welds, rail transition ramp building methods, Pandrol weld on shoulders, proper placement of work piece connections, and approved switch point welding procedures, as specified by the Burlington Northern Santa Fe Railway. This course will involve the study of different welding processes, welding safety, proper grounding techniques, rail heater and metallurgy. The effects of heat in relationship to specific rail steel components will be discussed. Students will be required to experience all appropriate methods and processes including welding, cutting, grinding, straight edging rail steel and preparing switch points for proper mating surface according to current industry standards. Evaluation will be a classroom and laboratory setting. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 137 Structural Welding SMAW (3 Hours)

Prerequisites: RRIT 123 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Upon successful completion of this course, the student should be qualified to weld with SMAW according to AWS D1.1.96 code. All welds will be made in the vertical (3G) and overhead (4G) positions. Passing or failing will be determined by the student's ability to successfully produce welds according to prescribed standards in AWS D1.1.96. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 138 Structural Welding FCAW (3 Hours)

Prerequisites: RRIT 137 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Upon successful completion of this course, the student should be qualified to weld with FCAW according to AWS D1.1.96 code. All welding will be made in the vertical (3G and 3F) and overhead (4G and 4F) positions. Passing or failing will be determined by the student's ability to successfully produce welds according to prescribed standards in AWS D1.1.96. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 140 Structural Quality SMAW (3 Hours)

Prerequisites: RRIT 127 or approval of the BNSF training director and the JCCC department approval

Upon successful completion of this course, the student should be qualified to weld with shielded metal arc welding (SMAW) according to industrial standards. Test welds will be made in the vertical up (3G) positions; limited thickness. Passing or failing will be determined by the student's ability to successfully produce welds according to prescribed American Welding Society (AWS) standards. The oxyfuel cutting (OFC) portion will include cutting metal to specific sizes and shapes. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 141 Structural Quality GMAW (3 Hours)

Prerequisites: RRIT 127 or approval of the BNSF training director and the JCCC department approval

Upon successful completion of this course, the student should be able explain the theory of gas metal arc (GMAW) identify materials and use equipment related to the processes. The student will weld on mild steel plate in all positions producing both fillet and groove welds with the GMAW process with a U-bend test being performed in selected positions according to industry standards. Selected welding codes and specifications will be used as a reference for this class. The oxy-fuel (OFC) will be used to prepare mild steel for welding. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 142 Structural Pile Welding (3 Hours)

Prerequisites: RRIT 137 and RRIT 138 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Upon successful completion of this course, the student should be able to splice pipe and H-beam piling and install cap plate gussets according to Burlington Northern Santa Fe (BNSF) standard blueprints. This course shall make use of oxy-fuel cutting (OFC), grinding, shielded metal arc welding (SMAW), and flux cored arc welding (FCAW) to prepare, fit and weld piling. Selected welds will have test strips bent to check for soundness of welds. These strips should meet basic American Welding Society (AWS) test standards. Basic metallurgy will be discussed as it applies to the need for preheat and post heat in the building of railroad bridges. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 145 Frog Welding (3 Hours)

Prerequisites: RRIT 123 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Upon successful completion of this course, the student should be able to repair by welding a manganese frog casting according to Burlington Northern Santa Fe Railway standards. This course will involve the study of different welding and cutting processes, with emphasis on the FCAW process. Metallurgy and the effects of heat in relationship to austenitic manganese steel will be discussed. Students will be required to cut, grind, straight edge, dye penetrant test, weld and monitor heat input during the repair process on austenitic steel frog casting for evaluation in an actual laboratory setting. 1 hr. lecture, 4 hrs. lab/wk.

RRIT 160 Mechanical Basic Welding (3 Hours)

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Upon successful completion of this course, the student should be able to properly use oxyfuel cutting (OFC), plasma arc cutting (PAC), plasma arc gouging, air carbon arc cutting (CAC-A), and shielded metal arc welding (SMAW) equipment. The SMAW portion of the course will concentrate on flat groove welds (1G) and horizontal fillet welds (1F). The student is required to pass a welding test in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1). 1 hour lecture 4 hours lab per week.

RRIT 162 Mechanical Welding Structural Stick (3 Hours)

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Upon successful completion of this course, the student should be able to properly use the shielded metal arc welding (SMAW) process on multi-pass groove welds in the horizontal (2G), vertical up (3G), and overhead (4G) positions. The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1). 1 hour lecture 4 hours lab per week.

RRIT 164 Mechanical Welding Structural Wire (3 Hours)

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Upon successful completion of this course, the student should be able to properly use the flux core arc welding (FCAW) process on multi-pass groove welds in the horizontal (2G), vertical up (3G), and overhead (4G) positions. The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1). 1 hour lecture 4 hours lab per week.

RRIT 166 Mechanical Welding Air Brake Pipe (3 Hours)

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Upon successful completion of this course, the student should be able to properly use the shielded metal arc welding (SMAW) and flux cored arc welding (FCAW) processes on pipe welds. The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1). 1hour lecture 4 hours lab per week.

RRIT 168 Mechanical Welding Sheet Metal (3 Hours)

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Upon successful completion of this course, the student should be able to properly use the gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) processes on sheet metal. The student is required to pass welding tests in accordance with the Railroad Welding Specification for Cars and Locomotives (AWS D15.1). 1 hour lecture 4hours lab per week.

RRIT 122

Title: Elements of Welding*
Number: RRIT-122
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 2
Lab Hours: 3

Description:

Prerequisites: Approval of the BNSF manager of track and roadway maintenance training and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Identify and practice appropriate shop safety rules.
Identify the basic welding joints and welding positions.
Demonstrate awareness of oxyfuel safety and setup procedures.
Display the ability to make a variety of OFC cuts.
Explain the basic theory of how the SMAW process works.
Demonstrate an understanding of SMAW electrodes and the AWS identification system.
Successfully produce a variety of welds using the SMAW process with a variety of electrodes.
Define and recognize basic metallurgy terminology as it pertains to ferrous metals.

Content Outline and Competencies:

I. Shop Safety Rules
   A. Identify BNSF and JCCC safety rules.
   B. Answer questions about commonly used safety rules in industry.
   C. Identify and select proper personal protective clothing and
equipment for OAW, OFC, SMAW, and grinding.
   D. List the parts of the fire triangle.
   E. Complete statements concerning basic safety rules for oxyfuel
cylinders and gases.
   F. Complete statements concerning eye protection.
   G. Complete a list of safety rules for the oxyfuel work area.
   H. List hazards concerning electrical safety for arc welding
   I. Select true statements concerning hazards associated with arc rays.
   J. Determine steps in selecting a safe lens shade.
   K. Select true statements concerning environmental safety
requirements.

II. Welding Joints and Positions
   A. List the five basic welding joints.
   B. Compare and contrast the 1G, 2G, 3G, 4G, 5G, and 6G welding
positions with the 1F, 2F, 3F, and 4F welding positions.

III. Oxyfuel Cutting
   A. Match terms with definitions.
   B. Select true statements concerning oxyfuel cutting characteristics.
   C. Identify parts of an oxyfuel cutting torch.
   D. Complete statements about cutting-tip design, cleaning, selection
and uses.
   E. Complete statements concerning control of kerf and drag.
   F. List reasons for poor cuts and elements of a good cut.
   G. Identify proper working surfaces for oxyfuel cutting.
   H. Identify special safety requirements for oxyfuel cutting.
   I. Complete statements concerning technique for cutting straight
lines.
   J. Demonstrate proper start up and shut down procedures.
   K. Demonstrate the ability to make the following cuts in the flat
position:
      1. Hand cutting straight cuts on 3/8" plate.
      2. Hand cutting bevel cuts on 3/8" plate.
      3. Piercing round and square holes in 3/8" plates.

IV. SMAW Welding Theory and Setup
   A. Match terms and definitions related to SMAW equipment, applications
and techniques.
   B. Define volts, amps, and watts and explain how each is controlled in
the SMAW process.
   C. Describe polarity.
   D. Compare and contrast constant current (C.C.) and constant voltage
(C.V.) power sources and know other common names for each.
   E. Explain when C.C. and C.V. should be used.
   F. Complete statements concerning basic SMAW accessories and purposes.
   G. Identify parts of an arc welder.
   H. Demonstrate the proper setup of a SMAW power source.
   I. Explain basic SMAW techniques.
   J. Match characteristics of good and bad welds with causes.
   K. List the five essentials of proper arc welding.
   L. Describe various bead running techniques.
   M. Explain two methods of initiating your arc in SMAW.
   N. Describe the proper technique for filling the crater at the
conclusion your weld.

VI. Electrode Use and Identification
   A. List the two main functions of the core wire.
   B. Describe at least five functions of the flux coating on a SMAW
electrode.
   C. Identify at least three organizations that have electrode
identification methods.
   D. Demonstrate the ability to use the AWS numbering system to identify
SMAW electrode characteristics.

VII. Shielded Metal Arc Welding Demonstration
   A. Demonstrate the correct setup of a SMAW welding station.
   B. Show the use of proper safety techniques while performing SMAW.
   C. Successfully produce the following welds using the SMAW process:
      1. Run flat beads with E7024..
      2. Run flat beads with E7018.
      3. Run flat beads with 6010.
      4. Build a single layer pad (flat position) with E6010.
      5. Build a single or multi layer pad (flat position) with E7018.
      6. Lap joint (2F position) E6010.
      7. Lap joint (2F position) E7018.
      8. Tee joint (2F position) E6010.
      9. Tee joint (2F position) E7018.
     10  Performance test (2F position) lap/tee E6010, E7018 & torch
cutting.

VIII. Metallurgy
   A. Match terms related to basic metals and metallurgy with
definitions.
   B. Identify reasons for proper metal identification.
   C. Identify alloy characteristics.
   D. Demonstrate the ability to conduct magnet tests and conduct chisel
tests.
   E. Match mechanical properties of metals with characteristics.
   F. Distinguish between types of mechanical strengths in metals.
   G. Match physical properties with characteristics of metals.
   H. Describe aspects of annealing, hardening and tempering processes.
   I. Select appropriate ways of testing metal properties.
   J. Match principal alloying agents of steel with characteristics.
   K. Match metals with ways to identify them by appearance.
   L. Solve problems concerning systems for identifying steel.
   M. Complete charts of carbon steel classifications, characteristics and
uses.
   N. Identify alloy steels by classification, characteristics and uses.
   O. Identify irons by classification, characteristics and uses.
   P. Identify equipment requirements for spark testing.
   Q. Conduct spark tests to identify common welding metals.

Method of Evaluation and Competencies:

Lab competencies will be assigned a level of competency on a scale
0-100, with 100 being high.

Lab Competencies                       60% of grade
Classroom/ Lab Participation           10% of grade
Quizzes and homework                   10% of grade
Midterm Test and Final (Written)       20% of grade
TOTAL                                 100%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) provide evidence that existing eyewear meets ANSI Z87.1, or 2) wear cover goggles (if allowable), or 3) purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

If you are a student with a disability, and if you will be requesting accommodations, it is your responsibility to contact Access Services. Access Services will recommend any appropriate accommodations to your professor and his/her director. The professor and director will identify for you which accommodations will be arranged.

JCCC provides a range of services to allow persons with disabilities to participate in educational programs and activities. If you desire support services, contact the office of Access Services for Students With Disabilities (913) 469-8500, ext. 3521 or TDD (913) 469-3885. The Access Services office is located in the Success Center on the second floor of the Student Center.

RRIT 123

Title: Basic Welding*
Number: RRIT-123
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: RRIT 122 or approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the proper use of the Shielded Metal Arc Welding (SMAW) process.
Identify SMAW variables.
Demonstrate the proper use of the Oxyfuel Cutting (OFC) process.
Select the electrodes required for SMAW.
Demonstrate Carbon Arc Cutting with air (CAC - A).
Demonstrate the ability to successfully weld selected lab projects.
Demonstrate the ability to successfully set up, weld, and test v-groove welds.
Identify the difference between welder qualification and welder certification.
Successfully pass a code quality V-groove guided U-bend test.

Content Outline and Competencies:

I. Shop Safety and Safety Rules.
   A. Identify BNSF and JCCC safety rules.
   B. Answer questions about commonly used safety rules in industry.
   C. Identify and select proper personal protective clothing and
equipment for OFC, SMAW, and grinding.
   D. List the parts of the fire triangle.
   E. Complete statements concerning basic safety rules for oxyfuel
cylinders and gases.
   F. Complete statements concerning eye protection.
   G. Complete a list of safety rules for the oxyacetylene work area.
   H. List hazards concerning electrical safety for arc welding
   I. Select true statements concerning hazards associated with arc rays.
   J. Determine steps in selecting a safe lens shade.
   K. Select true statements concerning environmental safety
requirements.

II. Shielded Metal Arc Welding (SMAW) Process
   A. Demonstrate the ability to accurately set up and shut down the SMAW
equipment.
   B. Demonstrate the operation of SMAW equipment by welding selected weld
joints in selected positions.
   C. Define the terms: Padding block, fire triangle, and duty cycle.
   D. List several main components used with the SMAW process.

III. SMAW Variables
   A. Use the correct current when welding on mild steel.
   B. Select according to industry standards the correct welding technique
for selected welds on mild steel.
   C. List advantages of straight polarity DCEN, reverse polarity DCEP,
and alternating current AC.
   D. Lists and define several factors that change the current value for
electrodes.

IV. Cutting (OFC) Process
   A. List components of the oxyfuel cutting torch.
   B. Explain the correct use of the welding and cutting tip selector
guide.
   C. Use the tip selection guide to obtain the correct tip size according
to material thickness.
   D. List factors to consider when selecting pressures and tip size.
   E. List several factors that determine a quality OAC cut.
   F. Use the oxyfuel cutting torch to cut and bevel mild steel.

V. Electrodes Required For SMAW
   A. Demonstrate the correct method to set up the SMAW process for
welding on mild steel.
   B. Demonstrate the successful welding of selected projects with SMAW.
   C. Demonstrate by welding using a CC power supply to successfully weld
steel using the correct
SMAW techniques.
   D. List several factors that determine the successful welding for mild
steel.

VI. Carbon Arc Cutting With Air (CAC - A)
   A. Identify the correct position and angle of the CAC-A electrode
required for the cutting and gouging of mild steel.
   B. Identify the correct electrode type for the CAC-A process.
   C. List factors to consider when cutting and gouging mild steel.
   D. Perform accurate cuts using the CAC-A process.

VII. Weld Selected Lab Projects
   A. Produce fillet welds in the 2F position using lap and tee joints.
   B. Select correct current requirements and position for selected
welds.
   C. Uses fillet weld gauge and other approved testing methods to
evaluate and test completed welds.

VIII. Certified and a Qualified Welder
   A. Define welder qualification.
   B. Define welder certification.
   C. List required steps a welder must take to be qualified.
   D. List required steps a welder must take to be certified

IX. Set Up, Weld, and Test V-groove Welds
   A. Use a welding fixture to gauge root gap for tack welding before weld
completion.
   B. Select correct current requirements and position for selected
welds.
   C. Demonstrate by welding selected test weld joints.
   D. Use appropriate methods to cut, clean and label weld test coupons.
   E. Demonstrate the use of the guided U-bend testing equipment.

X. Pass a Code Quality V-groove Guided U-bend Test
   A. Define the welding terms 1F and 1G.
   B. Demonstrate correct set up of welding fixture and tack welds into
positions for a V-groove test plate in the 1G weld position.
   C. Demonstrate by welding a V-groove test plate in the 1G weld position
according to industry standards.
   D. Demonstrate correct coupons selection for a face and root bend.
   E. Successfully pass the V-groove butt joint with backing test in a
selected 1G position.

Method of Evaluation and Competencies:

Lab Competencies               50% of grade
Classroom/Lab Participation    10% of grade
Quizzes                         5% of grade
Mid-term Test                   5% of grade
Final Written Test             10% of grade
Welding Lab Final              20% of grade
TOTAL                         100%

Lab competencies will be assigned a level of competency on a scale of
0-100, with 100 being high.

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) Provide evidence that existing eyewear meets ANSI Z87.1, or 2) Wear cover goggles (if allowable), or 3) Purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 132

Title: Thermite Welding*
Number: RRIT-132
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: Approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Explain the basic process and chemical reaction.
Identify and practice appropriate safety practices and rules in the performance of a Thermite weld.
Analyze and explain quality assurance or quality control measures and documentation required for proper completion of welding various sizes of rail.
Align various profiles of track using wedges and alignment frames.
Explain the proper procedure for sawing, cleaning, cutting, trimming and preparing rail ends.
Produce as welder in-charge, multiple Rail Tech and Orgo Therm or comparable welds.
Align, assemble, fit and pack Orgo Therm and Rail Tech or comparable molds on new to new, head worn to new, gauge face worn to gauge face worn and transposed rail.
Describe the safe use and use torches in a safe manner.
Describe various terms related to metallurgy and relate them to the use of temperature indicating devices.
Tear down or remove the ’hot’ mold and weld in a safe manner.
Perform the rough and finish grinding operations correctly and in a safe manner.
Explain and apply procedures and rules as listed in the BNSF Orgo Therm and the BNSF Rail Tech manuals.

Content Outline and Competencies:

I. An Overview of the Basic Thermite Process
   A. Explain the chemical reaction of Thermite steel.
   B. Check the temperature at various points in time and location.
   C. Describe the effect of moisture on slag and Thermite steel.
   D. Describe the recommended disposal of unused Thermite.

II. Safety
   A. Identify BNSF and JCCC safety rules.
   B. Answer questions about commonly used safety rules in industry.
   C. Identify and select proper personal protective equipment for
Thermite welding and grinding.
   D. List the parts of the fire triangle.
   E. Complete statements concerning eye protection.
   F. Complete statements concerning basic safety rules for oxy-fuel
cylinders and associated gases.
   G. Complete a list of safety rules for the thermite work area.
   H. Select true statements concerning environmental safety
requirements.
   I. Liquid oxygen safety
      1. Describe the construction of the GP-22 or GP-45.
      2. Explain the operation and purpose of safety valves.
      3. Explain the gas use valve.
      4. Explain the liquid valve.
      5. Explain the pressure building valve.
      6. Demonstrate the safe set-up and operation of liquid oxygen used
with a fuel gas.
   J. Propane safety
      1. Describe the construction of the propane cylinder.
      2. Describe the safety valve.
      3. Describe the use valve.
   K. Regulator and torch safety
      1. Describe single stage regulators.
      2. Describe flow check valves vs. flashback arrestors.
      3. Explain types and uses of hoses.
      4. Select and use the proper torch handle.
      5. Select and use the proper cutting attachment.
      6. Select and use the proper torch tip.
   L. Grinder and saw safety
      1. Check rpm of equipment.
      2. Check condition of blades and stones.
      3. Wear proper protective equipment.
      4. Operate grinders and saws safely.
   M. Personal safety
      1. Wear approved hard hat.
      2. Wear approved safety glasses.
      3. Wear approved shaded eye protection.
      4. Wear approved boots.
      5. Wear approved gloves.
      6. Wear approved goggles.
      7. Wear approved face shield.
   N. Demonstrate the proper use of measuring tools, specialized Thermite
tools, hand tools, shearing tools, jacks and other tools and supplies
associated with welding rail with the Thermite welding process in a safe
manner.

III. Quality
   A. Complete a production welding report.
   B. Complete a quality welding report.
   C. Document adding or subtracting rail.

IV. Alignment Procedures
   A. Preparation – general restrictions/limitations
      1. Remove spikes or clips
      2. Saw joint or plug to fit the crib
      3. Square ends
      4. Document addition or subtraction of rail
      5. Clean rail ends
      6. Torch clean rails
      7. Document rail height
      8. Review temperature and weather conditions
      9. Examine rail requirements
     10. Observe rail movement/traffic restrictions
     11. Review track work preparation
     12. Review track concrete and wood tie requirements
     13. Review rail end preparation
     14. Explain alignment of 115#, 132#, 136# and 141#
   B. Rough crown
      1. Use a 36" steel straight edge
      2. Use a magnetic straight edge
      3. Eyeball the track
      4. Set correct dimensions
      5. Check elevation of mismatch
      6. Use the taper gage
      7. Offset vertical mismatch in the base only
   C. Base
      1. Use a 36", 1 meter or 18" straight edge
      2. Align gage side base whenever possible
   D. Ball
      1. Use a 36" or 1 meter straight edge
      2. Align gage side ball whenever possible
   E. Final alignment
      1. Check web
      2. On mismatched rail check field side alignments, as a reference
      3. Set final crown
      4. Recheck all

V. Rail Cutting
   A. Use rail saws in a safe manner
   B. Use oxyfuel cutting torch to cut rail as required to remove
expansion
   C. Clean rail ends as needed

VI. Complete Welds
   A. Perform a Rail Tech weld from start to finish
   B. Perform an Orgo Therm weld from start to finish
   C. Perform a third weld from start to finish
   D. The welder’s responsibility
      1. Insure rail end preparation is done correctly
      2. Insure proper alignment is done correctly
      3. Check mold installation
      4. Check mold packing
      5. Keep track of all times and temperatures
      6. Insure grinding is done properly
      7. Insure quality documentation is recorded
      8. Insure sawing and grinding are done properly
E. The grinder’s or helper’s responsibilities
      1. Perform or assist welder with sawing and grinding operations
      2. Assist the welder in the performance of his/her duties

VII. Mold Application
   A. Arrange for the preparation to apply the molds
   B. Complete and check the packing of molds
   C. Do filing as required
   D. Complete and check the installation of the molds and hardware

VIII. Current Brand of Torch
   A. Explain the operation of the Victor brand
   B. Explain the operation and use the Hesa/SkV brand as needed.

IX. Metallurgy
   A. Describe head hardened rail
   B. Describe standard carbon rail
   C. Describe time at temperature
   D. Describe preheat
   E. Describe postheat
   F. Describe a rail end that is too cold and too hot during preheating

X. Mold Tear Down or Removal
   A. Remove hardware
   B. Crop the top of the mold
   C. Use shear or hot-cut only when needed
   D. Cover the weld according to conditions

XI. Grinding
   A. Rough grind the weld
   B. Finish grind the weld
   C. Use a 36" or 1 meter straight edge during finish grinding

XII. Process Rules and Procedures
   A. Review Rail Tech procedures
   B. Review Orgo Therm procedures

Method of Evaluation and Competencies:

Multiple Thermite welds will be assigned a score of 1-10. Check-off
sheets used in the welding area are the student's responsibility. 

The final grade will be calculated as follows:

Participation         10% of grade
Lab competencies      60% of grade
Two quizzes           10% of grade
Final test            20% of grade
TOTAL                100%

The lab competencies grade (60%) will be a composite of multiple
welding/grinding grades, additional comments recorded on lab sheets
following the procedures, the overall use of time, the completion of lab
work and successfully completing your own work.

Caveats:

Students need to be prepared to work in bad weather conditions. Lab activity is out-of-doors.
Students must wear proper safety equipment, no exceptions.
Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) Provide evidence that existing eyewear meets ANSI Z87.1, or 2) Wear cover goggles (if allowable), or 3) Purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 136

Title: Rail and Switch Point Repair Welding*
Number: RRIT-136
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: RRIT 123 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate safety at all times, to include: follow all safety rules and all safety procedures using related cutting, welding and grinding processes. Oxy-Propane heating, SMAW, FCAW processes, hydraulic rail saws, and grinding equipment, personal protective equipment PPE, and apparatus of all types.
Locate, identify and select controls, switches, dials, levers, buttons, guards, and operating and grounding devices related to welding power supplies, hydraulic rail saws, grinders, electrical test meters and manual gauging devices.
Prepare rail steel and switch points for welding by performing correct grinding and heating procedures according to current industry standards, and welding repair manuals.
Identify metallurgical effects that take place in carbon and high carbon steel as the steel is heated and cooled.
Select correct current when operating welding machines (power supplies), i.e., Constant Current (CC) or Constant Voltage (CV).
Select the approved electrode type, size, and parameters for the process being used for the repair of rail and switch point steel.
Perform maintenance and repairs on rail steel, switch points and related cutting and grinding equipment according to the current welding repair manual.
Demonstrate the ability to successfully contour rail steel using the approved grinding techniques and gauging tools.
Describe several styles and sizes of formerly used, and currently used switch points.
Use the approved dye penetration methods and gauging tools used to test welded repairs made to the surface of the rail steel and switch points after welding and grinding.

Content Outline and Competencies:

I. Safety
   A. Follow the correct and approved safety rules and procedures
according to JCCC and BNSF safety sheets.
   B. Use PPE when welding, cutting, sawing, grinding, and testing
procedures on rail steel and switch points.
   C. Demonstrate correct and safe methods to set up, use and shut down
the hydraulic power units, and the tools associated with the equipment. 
   D. Demonstrate the correct and safe method to set up and shut down the
oxy-propane torch.
   E. Demonstrate safety procedures when operating hydraulic rail saws and
grinding equipment.
   F. Demonstrate proper procedures when operating welding equipment.
   G. Demonstrate the correct and safe method to set up and shut down the
SMAW and FCAW equipment.
   H. List safety rules for welding, cutting, hydraulic rail saws, and
grinding equipment.

II. Identify and locate various controls on equipment related to repairing
rail steel and switch points.
   A. Select correct amperage and voltage required for the operation of
welding power supplies.
   B. Use a multi-meter to accurately measure welding voltages and welding
amperage at the welding arc.
   C. Demonstrate the appropriate, correct and safe method of installing
the (ground clamp) work piece connection.
   D. Perform accurate cuts using a hydraulic rail saw.
   F. Perform accurate grinding on rail steel and switch points using
appropriate grinding stones to contour rail steel and mating surfaces of
switch points to meet industry standards.

III. Prepare rail steel and switch points for welding.
   A. Use current welding repair manual to select correct repair
procedures.
   B. Demonstrate correct methods to repair rail steel and switch points
by welding and grinding.
   C. Select the correct process, SMAW or FCAW  for the repair of rail
steel and/or switch points according to the current welding repair
manual.
   D. List current industry standards for the repair of rail steel and
switch points.

IV. Identify metallurgical effects of welds made when repairing rail steel
and switch points.
   A. Explain the purpose for preheat, interpass temperature, and post
heat.
   B. Explain selected metallurgical terms.
   C. Explain the approved electrode composition for the SMAW and FCAW
processes.
   D. Demonstrate the proper use of temperature sensing devices.
   E. List and define metallurgical effects of welds made when repair
welding rail steel and switch points.

V. Select correct current when operating welding power supplies.
   A. Identify the correct welding electrode type for SMAW of rail steel
and switch points.
   B. Identify the correct welding electrode type for FCAW of rail steel
and switch points.
   C. Select the correct parameters (amps) for the SMAW process when
welding on rail steel and Switch points.
   D. Select the correct parameters (volts) for the SMAW process when
welding on rail steel and Switch points.
   E. List factors that determine the type, size, and parameters when
selecting electrodes.

VI. Select the approved electrode for the repair of (Pandrol Plates) mild
steel.
   A. Identify the correct electrode type for the FCAW process.
   B. Select the correct parameters (volts) for FCAW electrodes.
   C. List factors that determine the type, size and parameters when using
FCAW.

VII. Perform maintenance and repairs on rail steel and switch points, and
pandrol weld on shoulders according to industry standards. 
   A. Perform minor maintenance on welding equipment, i.e., power
supplies, hydraulic units, work piece connections, hydraulic rail saws and
grinders, cables, electrode holders, wire feed units and wire feed guns,
oxy-propane  equipment. 
   B. Demonstrate by welding to industry standards, Pandrol
(weld-on-shoulder) with the FCAW process.
   C. List steps and/or methods used when making minor repairs to
equipment used to maintain rail steel and switch points.

VIII. Demonstrate the correct technique to successfully contour radius and
straight edge rail steel and switch point mating surfaces.
   A. Select correct hydraulic grinding equipment.
   B. Perform grinding techniques and procedures according to current
welding manual.
   C. List tools required to check contour, straight edge, radius and
mating surface for rail steel and switch points. 
   D. Use correct technique and approved gauges to verify and conform
radius and running surface of repaired rail and mating surfaces for switch
points.

IX. Switch point styles and sizes.
   A. Follow approved practices and the current welding repair manual to
identify switch point types and sizes.
   B. Explain reasons for preventive grinding of switch points.
   C. Identify general requirements for the repair of switch points
   D. Define common sizes of selected switch points to include:
      1. Knife Point switch point
      2. Samson switch point
   E. Demonstrate switch point preparation for grinding.
   F. Demonstrate switch point welding repair.
   G. Demonstrate switch point finish grinding.
   H. Demonstrate switch point mating surface check
   I. List essentials needed when determining if repairs are required.

X. Perform dye penetration procedures to successfully check welded rail
and switch point for surface defects.
   A. Select approved dye penetrant solution.
   B. Apply dye penetrant in a safe and correct manner.
   C. Inspect rail and switch point surface for flaws or defects.
   D. List steps to successfully perform the dye penetrant test on rail
steel and/or switch points.

Method of Evaluation and Competencies:

Note: Lab competencies will be assigned a level of competency of 0-10,
10 being high.

Demonstrate by achieving 100% on a safety test.
Demonstrate by achieving a minimum of 90% each on two quizzes.

      Lab competencies         50% of grade
      Participation            10% of grade
      Classroom/quizzes        10% of grade
      Mid-term exam            10% of grade
      Written final exam       20% of grade
       TOTAL                   100%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A.72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) provide evidence that existing eyewear meets ANSI Z87.1, or 2) wear cover goggles (if allowable), or 3) purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 137

Title: Structural Welding SMAW*
Number: RRIT-137
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: RRIT 123 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Identify and practice appropriate shop safety rules.
Identify welding joints and welding positions.
Demonstrate an understanding of welding electrodes and AWS identification system.
Demonstrate an understanding of the Oxy-Fuel Cutting (OFC) process.
Demonstrate proper handling and manipulation of an OFC torch.
Explain the concepts, process, and demonstrate the skills of the Shielded Metal Arc Welding (SMAW) process.
Produce welds with SMAW that meets code requirements.
Produce welds with SMAW in the 3 G vertical up position that meets code requirements.
Produce welds with SMAW in the 4 G over head position that meets code requirements.

Content Outline and Competencies:

I. Shop Safety Rules
   A. Identify BNSF and JCCC safety rules and describe specific
differences.
   B. Answer questions about commonly used safety rules in the welding
industry.
   C. Identify and select proper personal protective clothing and
equipment for OFC and SMAW.
   D. Identify the parts of a fire triangle.
   E. Demonstrate appropriate safety measures in most common arc and gas
welding situations.

II. Welding Joints and Welding Positions
   A. Properly prepare welding joints lap, tee, and butt.
   B. Identify the five types of joints and variations.

III. Codes and Standard Used in the Welding Industry
   A. Explain the AWS D1.1 code standards.
   B. Identify the characteristics of the V-butt code test in the 3G and
4G positions.
   C. Identify the proper sequence of beads in the v-butt joint.
   D. Evaluate weld quality ( defects, discontinues ).
   E. Demonstrate proper technique for preparing bend test.

IV. Oxy-Fuel Cutting (OFC) Process
   A. Identify safety devices on oxygen and acetylene cylinders.
   B. Demonstrate safe handling of gas cylinders
   C. Explain why high pressure cylinders utilize double seating valves.
   D. List basic safety rules when using oxygen and acetylene.

V. Proper Handling and Manipulation of an OFC Torch
   A. Safely and properly follow the procedure to set up, light, and shut
down an oxy-acetylene cutting torch.
   B. Make OFC straight and beveled cuts with/without straight edges.

VI. Demonstrate an understanding of the Shielded Metal Arc Welding (SMAW)
Process
   A. Explain the SMAW process.
   B. Explain duty cycle.
   C. Explain the relationship between arc length and arc voltage.
   D. Describe the numbering systems for gas and arc welding lens.
   E. Describe the difference between a weave bead and a stringer bead.
   F. Explain the fundamental theory of arc welding.
   G. Explain the difference between constant current and constant
voltage.
   H. Describe arc blow.
   I. Demonstrate the use of current controls.
   J. Re-define selected terms in glossary that refer to SMAW.
   K. Explain the difference in heat release with DCEN, DCEP and AC.
   L. Distinguish between fusion and penetration.
   M. Identify the typical electric circuit for shielded metal-arc
welding.
   N. Distinguish between open circuit voltage and operating voltage.
   O. Identify different types of power sources.
   P. Describe polarity and parameters.
   Q. Explain why electrode holder, workpiece connections, cable lugs, and
cables should match amperage ratings.

VII. Produce a 3G V-butt weld with backing that meets code quality.

VIII. Produce a 4G V-butt weld with backing that meets code quality.

Method of Evaluation and Competencies:

Lab competencies will be assigned a level of competency on a scale of
0-10, with 10 being high.

3G-4G Weld Test         60% of grade
Lab Competencies        10% of grade
Quizzes                 10% of grade
Participation           10% of grade
Final                   10% of grade
TOTAL                   100%

Caveats:

All students must pass all four bend tests in order to be assured of at least a “C” letter grade.
Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) provide evidence that existing eyewear meets ANSI Z87.1, or 2) wear cover goggles (if allowable), or 3) purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 138

Title: Structural Welding FCAW*
Number: RRIT-138
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: RRIT 137 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Identify and practice appropriate shop safety rules.
Identify the basic welding joints and welding positions.
Explain the basic theory of how the FCAW process works.
Select proper electrode and welding procedures according to the steel being welded.
Demonstrate an understanding of the AWS D1.1.96 code, as it pertains to qualification testing for unlimited thickness, in the 3G & 4G positions, using FCAW.
Perform lab competencies as assigned.

Content Outline and Competencies:

I. Shop Safety Rules
   A. Identify BNSF and JCCC safety rules.
   B. Answer questions about commonly used safety rules in industry.
   C. Identify and select proper personal protective equipment (PPE) and
clothing for oxy-fuel cutting and FCAW welding in the vertical and
overhead positions.
   D. Identify and select correct PPE for grinding.
   E. Complete statements concerning basic safety rules for oxy-acetylene
cylinders and gasses.
   F. Complete statements concerning eye protection.
   G. Complete a list of safety rules for the oxy-acetylene work area.
   H. List hazards concerning electrical safety for arc welding.
   I. Select true statements concerning hazards associated with arc rays.
   J. Determine steps in selecting a safe lens shade.
   K. Select true statements concerning environmental safety
requirements.

II. Welding Joints and Positions
   A. List the five basic welding joints.
   B. Compare and contrast the 1G, 2G, 3G, 4G, 5G, and 6G welding
positions with the 1F, 2F, 3F, and 4F welding positions.
   C. Identify weld nomenclature.

III. FCAW Welding Theory
   A. Identify specific components of the FCAW welding equipment.
   B. Compare and contrast the use of constant voltage (C.V.) and constant
current (C.C.) in the FCAW process.
   C. Explain the effects of stickout when using C.V. and C.C. when using
the FCAW process.
   D. List the five essentials of arc welding.
   E. Demonstrate the proper setup of a FCAW power source.
   F. Explain basic FCAW techniques.
   G. Match characteristics of good and bad welds with causes.
   H. Describe various bead running techniques.
   I. Describe the proper techniques for filling the crater at the
conclusion of your weld.
   J. Compare and contrast different bead sequencing techniques.

IV. Metallurgy and Filler Metal Selection
   A. Describe carbon equivalency and why it is important.
   B. Explain why preheat is important and when and how it should be
used.
   C. Identify factors that will determine filler metal selection.
   D. Explain E71T-8 using the AWS electrode identification system.
   E. Compare and contrast E71T-8 with #70T-10 electrode.

V. Qualification Requirements AWS D1.1.96
   A. Describe the metal thickness requirements to be qualified for
unlimited thickness.
   B. Explain the joint fit-up required for unlimited thickness.
   C. Identify where test strips will be cut from in weld sample.
   D. List the acceptability standards for the test specimens to pass.
   E. Explain how long certification is good for.
   F. Describe what positions and joints you are qualified to weld if you
pass the 3G and 4G test.
   G. Describe the preheat procedure for one inch A36 steel.
   H. Explain visual acceptance criteria for qualification test.

VI. Perform the Following Lab Competencies (All welds use E71T-8
electrode)
   A. Set-up and properly maintain a FCAW welding station.
   B. Perform a multi-pass fillet weld in the 3F up and 4F positions.
   C. Demonstrate the ability to weld simulated V-butts with backing in
the 3G up and 4G position.
   D. Inspect selected simulated V-butts with backing for slag using a
cutting torch.
   E. Assemble and align, and tack a V-butt joint with backing.
   F. Deposit a root pass on a grooved joint in the 3G up position and 4G
position.
   G. Deposit filler passes on a grooved joint in the right sequence 3G
and 4G position.
   H. Demonstrate proper cleaning procedure between weld passes.
   I. Demonstrate proper weld technique in bead sequencing of the cover
pass 3G up and 4G.
   J. Inspect finished weld to determine its quality (defects) (visual
inspection to be done by the instructor prior to destructive testing).
   K. Demonstrate proper techniques in preparing test coupons.
   L. Pass the required destructive bend tests (FCAW).

Method of Evaluation and Competencies:

3G-4G Test                     60% of grade
Lab                            10% of grade
Ouiz and Homework              10% of grade
Classroom/Lab Participation    10% of grade
Final                          10% of grade
TOTAL                         100%

Caveats:

All students must pass all bend tests in order to be assured of at least a “C” letter grade.
Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) provide evidence that existing eyewear meets ANSI Z87.1, or 2) wear cover goggles (if allowable), or 3) purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 140

Title: Structural Quality SMAW*
Number: RRIT-140
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: RRIT 127 or approval of the BNSF training director and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Identify and practice appropriate shop safety rules.
Identify basic welding joints and welding positions.
Demonstrate an understanding of welding electrodes and AWS identification system.
Identify basic characteristics of various metals.
Demonstrate an understanding of the Oxy-Fuel Cutting (OFC) process.
Demonstrate proper handling and manipulation of an OFC torch.
Explain the concepts, process, and demonstrate the skills of the Shielded Metal Arc Welding (SMAW) process.
Produce weld beads with SMAW in the flat, horizontal, and vertical positions.
Produce fillet welds with SMAW in the flat, horizontal, and vertical positions.
Produce groove welds with SMAW in the flat position.

Content Outline and Competencies:

I. Shop Safety Rules
   A. Identify BNSF and JCCC safety rules and describe specific
differences.
   B. Answer questions about commonly used safety rules in the welding
industry.
   C. Identify and select proper personal protective clothing and
equipment for OFC and SMAW.
   D. Identify the parts of a fire triangle.
   E. Demonstrate appropriate safety measures in most common arc and gas
welding situations.

II. Identify Basic Welding Joints and Welding Positions
   A. Properly prepare welding joints; lap, tee, and v-groove butt.
   B. Identify the five types of joints and variations.

III. Welding Electrodes and AWS Identification System
   A. Properly set the amperage control for the electrode size, type, and
position being used.
   B. Describe factors that change current values for electrodes.
   C. Identify the A.W.S. number system for mild steel electrodes.
   D List the four classification groups of the A.W.S. mild steel
electrodes, and
   E. Identify their characteristics.
   F. Explain the functions of the electrode's covering.
   G. Identify different size rod ovens.

IV. Identify Basic Characteristics of Various Metals
   A. Identify ferrous non-ferrous metals.
   B. Describe physical properties of metal.
   C. List the effects of various alloys used in steel.
   D. Identify carbon content in the three groups of carbon steel.
   E. Explain the color scale in relationship to temperature data.
   F. Describe the reasons for preheating, interpass, and post heating.

V. Oxy-Fuel Cutting (OFC) Process
   A. Identify safety devices on oxygen, acetylene and propane cylinders.
   B. Describe how acetylene gas is made and stored.
   C. Describe the fundamentals of combustion.
   D. List basic safety rules when using oxygen, acetylene and propane.
   E. Explain the reaction when acetylene comes into contact with
unalloyed copper.
   F. Demonstrate safe handling of gas cylinders.
   G. Explain why high pressure cylinders utilize double seating valves.

VI. Proper Handling and Manipulation of an OFC Torch
   A. Safely and properly follow the procedure to set up, light, and shut
down an cutting torch.
   B. Make OFC straight cuts with or without a guide on 3/8" steel plate.

VII. Demonstrate an understanding of the Shielded Metal Arc Welding (SMAW)
Process
   A. Explain the SMAW process.
   B. Explain five essentials of arc welding.
   C. Describe the two methods for starting an arc.
   D. Describe the numbering systems for gas and arc welding lens.
   E. Describe the difference between a weave bead and a stringer bead.
   F. Explain the fundamental theory of arc welding.
   G. Describe polarity and parameters.
   H. Describe arc blow.
   I. Explain the relationship between arc length and arc voltage.
   J. Identify selected terms in glossary that refer to SMAW.
   K. Explain the difference in heat release with DCEN, DCEP and AC.
   L. Distinguish between fusion and penetration.
   M. Identify the typical electric circuit for shielded metal-arc
welding.
   N. Explain the difference between constant current and constant
voltage.
   O. Identify different types of power sources.
   P. Distinguish between open circuit voltage and operating voltage.
   Q. Demonstrate the use of current controls.
   R. Explain duty cycle.
   S. Explain why electrode holder, work piece connections, cable lugs,
and cables should match recommended amperage ratings.

VIII. Weld Beads with SMAW in the Flat, Horizontal, and Vertical
Positions
   A. Produce stringer beads with E 6010, making 2 tie-ins in each bead in
the flat, horizontal, and vertical positions.
   B. Produce stringer beads with E 7018, making 2 tie-ins in each bead in
the flat, horizontal, and vertical positions.

IX. Produce Fillet welds with SMAW in the Horizontal, and Vertical
Positions, including:
   A. Fillet weld lap joints using E 6010 in the 2F position.
   B. Fillet weld lap joints using E 7018 in the 2F position.
   C. Fillet weld tee joints using E 6010 in the 3F position. (up)
   D. Fillet weld tee joints using E 7018 in the 3F position. (up)
   
X. Produce Groove welds with SMAW in the Vertical Positions (up),
including:
   A. V-groove butt joint without backing using E6010 and E 7018 in the 3G
position (up).
   B. Final bend test in the 3G position.

Method of Evaluation and Competencies:

Lab competencies will be assigned a level of competency on a scale of
0-10, with 10 being high.

Lab Competencies                60% of grade
Classroom/Lab Participation     10% of grade
Quizzes                         10% of grade
Mid Term Test                    5% of grade
Final Written Test              10% of grade
Bend tests                       5% of grade
TOTAL                          100%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities for this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72- 5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1. provide evidence that existing eyewear meets ANSI Z87.1, or 2. wear cover goggles (if allowable), or 3. purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 141

Title: Structural Quality GMAW*
Number: RRIT-141
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: RRIT 127 or approval of the BNSF training director and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Identify and practice appropriate shop safety rules.
Identify basic welding joints and welding positions.
Identify welding electrodes and AWS identification system.
Identify basic characteristics of various metals.
Perform the Oxy-Fuel Cutting (OFC) process.
Demonstrate proper handling and manipulation of an OFC torch.
Perform the Plasma Arc Cutting (PAC) process on steel plate.
Demonstrate proper handling and manipulation of a PAC torch.
Explain the concepts, process, and demonstrate the skills of the Gas Metal Arc Welding (GMAW) process.
Produce weld beads with GMAW in the flat, horizontal, vertical, and overhead positions.
Produce fillet welds with GMAW in the horizontal, vertical, and overhead positions.
Produce groove welds with GMAW in the horizontal, vertical, and overhead positions.

Content Outline and Competencies:

I. Shop Safety Rules
   A. Identify BNSF and JCCC safety rules and describe specific
differences.
   B. Answer questions about commonly used safety rules in the welding
industry.
   C. Identify and select proper personal protective clothing and
equipment for OFC and GMAW.
   D. Identify the parts of a fire triangle.
   E. Demonstrate appropriate safety measures in most common arc and gas
welding situations.

II. Basic Welding Joints and Welding Positions
   A. Properly prepare lap, tee, and v-groove welding joints.
   B. Identify the five types of joints and variations.

III. Welding Electrodes and AWS Identification System
   A. Properly set the amperage control for the electrode size, type, and
position being used.
   B. Describe factors that change current values for electrodes.
   C. Identify the A.W.S. number system for mild steel electrodes.
   D. List the various A.W.S. classifications for GMAW solid wires. 
   E. Explain the functions of the copper-coated and copper-less, solid
wire.

IV. Basic Characteristics of Various Metals
   A. Identify ferrous and non-ferrous metals.
   B. Describe physical properties of metal.
   C. List the effects of various alloys used in steel.
   D. Identify carbon content in the three groups of carbon steel.
   E. Explain the color scale in relationship to temperature data.
   F. Describe the reasons for preheating, interpass, and post heating.

V. Oxy-Fuel Cutting (OFC) Process
   A. Identify safety devices on oxygen, acetylene and propane cylinders.
   B. Describe how acetylene and propane gas is made and stored.
   C. Describe the fundamentals of combustion.
   D. List basic safety rules when using oxygen, acetylene, and propane.
   E. Explain the reaction when acetylene comes into contact with
unalloyed copper.
   F. Demonstrate safe handling of gas cylinders.
   G. Explain why high pressure cylinders utilize double seating valves.

VI. Plasma Arc Cutting (PAC) Process
   A. Explain the principles of plasma arc cutting.
   B. Describe the required equipment for PAC.
   C. Describe the gas requirements for PAC.
   D. List basic safety rules when using the PAC process.

VII. Proper Handling and Manipulation of an OFC Torch
   A. Safely and properly follow the procedure to set up, light, and shut
down an oxy-propane cutting torch.
   B. Make OFC straight cuts with and without a guide on 3/16" steel
plate.

VIII. The Gas Metal Arc Welding (GMAW) Process
   A. Explain the GMAW process.
   B. Explain five essentials of arc welding.
   C. Describe the numbering systems for gas and arc welding lens.
   D. Describe the difference between a weave bead and a stringer bead.
   E. Explain the fundamental theory of arc welding.
   F. Describe polarity and parameters.
   G. Explain the relationship between electrode extension and arc
amperage.
   H. Identify selected terms in glossary that refer to GMAW.
   I. Distinguish between fusion and penetration.
   J. Identify the typical electric circuit for gas metal-arc welding.
   K. Explain the difference between constant current and constant
voltage.
   L. Identify different types of power sources.
   M. Distinguish between open circuit voltage and operating voltage.
   N. Demonstrate the use of current and voltage controls.
   O. Explain duty cycle.
   P. Explain why GMAW gun, workpiece connections, cable lugs, and cables
should match recommended amperage ratings.

IX. Weld Beads with GMAW in the Horizontal, Vertical, and Overhead
Positions
   A. Produce stringer beads, making 2 tie-ins in each bead in the
horizontal, vertical, and overhead
positions.
   B. Produce a pad of beads as applied to building up a surface.

X. Fillet Welds with GMAW in the Flat , Horizontal, and Vertical
Positions, including:
   A. Fillet weld in the 2F position.
   B. Fillet weld in the 3F position (up).
   C. Fillet weld in the 3F position (down).

XI. Groove Welds with GMAW in the Flat, Horizontal and Vertical Positions,
including:
   A. Square groove butt joints in the 1G, 2G, and 3G position.
   B. V-groove butt joint in the 2G position.
   C. V-groove butt joint in the 3G position.
   D. Final selected weld bend tests in the 2G, 3G, or 4G positions.

Method of Evaluation and Competencies:

Lab competencies will be assigned a level of competency on a scale of
0-10, with 10 being high.

Lab Competencies                 50% of grade
Classroom/Lab Participation      10% of grade
Quizzes                          10% of grade
2G Performance Exam               5% of grade
3G Performance Exam               5% of grade
Mid Term Exam                     5% of grade
Final Exam                       15% of grade
TOTAL                           100%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities for this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72- 5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. NOTE: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1. provide evidence that existing eyewear meets ANSI Z87.1, or 2. wear cover goggles (if allowable), or 3. purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 142

Title: Structural Pile Welding*
Number: RRIT-142
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: RRIT 137 and RRIT 138 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Identify and practice appropriate shop safety rules.
Explain a variety of testing and inspection methods and why they are used.
Perform weld tests and evaluate according to given standard or code.
Compare and contrast different welding processes and procedures.
Explain the reasons for pre and post heat when welding.
Demonstrate a basic understanding of blueprint reading.
Discuss and demonstrate correct pipe and H-beam preparation and fit up techniques.
Demonstrate skill in welding pipe and H-beam in the 2G position using both SMAW
and FCAW.

Content Outline and Competencies:

I. Shop Safety Rules
   A. Identify BNSF and JCCC safety rules.
Select true statements concerning safe clothing requirements.
   B. Identify statements concerning basic safety rules for oxyacetylene
cylinder and gases.
   C. Complete statements concerning eye protection.
   D. Demonstrate the safe way of setting up oxyacetylene equipment.
   E. Define SMAW an FCAW safety terms.
   F. Complete statements concerning important rules for safe handling of
welding cables.
   G. Compare and contrast different types of welding hoods.
   H. Determine steps in selecting a safe lens shade.
   I. Select true statements concerning environmental safety
requirements.

II. Testing and Inspection
   A. Describe the difference between mechanical and non-destruction (NDT)
testing.
   B. List the twelve cost common discontinuities and the methods used to
locate them.
   C. Explain why welds are tested.
   D. List the four most common root defects and the causes of each
defect.
   E. Discuss qualification standards for welding according to the AWS
D1.1.96 code.
   F. Evaluate a weld according to AWS D1.1.96 code parameters.

III. Welding Processes and Procedures
   A. Describe the advantages of using different electrodes.
   B. Compare and contrast the advantages and disadvantages of SMAW and
FCAW for pile welding.
   C. Describe the advantages and disadvantages of stringer and weave
beads.
   D. Discuss reasons for pre and post heat

IV. Joint Preparation and Fit Up
   A. Properly interpret blueprints to obtain proper joint fabrication and
tolerances.
   B. List the basic piling joints.
   C. Compare and contrast an open joint to using a chill ring.
   D. Discuss fish plating.
   E. List causes and cures of fit up problems.
   F. Explain lands and root openings.
   G. Prepare pipe joints and H-beam joints for welding using a torch and
grinder.
   H. Align, fit up, and tack straight joints for welding in the 2G
position.
   I. Demonstrate the ability to prepare and tack weld fish plates on
piling.
   J. Prepare and fit up gussets on cap plates.

V. Pile Welding
   A. Demonstrate ability to run root passes in the 2G.
   B. Display the ability to run hot passes in the 2G.
   C. Exhibit expertise in running filler and cover passes in the 2G
position.
   D. Demonstrate the ability to weld fish plate on H-beam piling.
   E. Weld gussets onto cap plates and piling.

Method of Evaluation and Competencies:

   Bend Test         20%
   Lab               60%
   Participati       10%
   Mid Term           5%
   Final Exam         5%
   TOTAL            100%

   Grade Criteria:
   A = 90-100
   B = 80- 89
   C = 70- 79
   D = 60- 69
   F =  0- 59

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) provide evidence that existing eyewear meets ANSI Z87.1, or 2) wear cover goggles (if allowable), or 3) purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 145

Title: Frog Welding*
Number: RRIT-145
Effective Term: Spring 2009
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisites: RRIT 123 and approval of the BNSF manager of engineering and maintenance training and the JCCC department approval

Course Fees:

None

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate safety at all times, to include: follow all safety rules and all safety procedures using Carbon Arc Cutting with Air (CAC-A), SMAW, FCAW processes, rail saws, and grinding equipment, personal protective equipment PPE, and apparatus of all types.
Locate, identify and select controls, switches, dials, levers, buttons, guards, and operating devices related to welding power supplies, Carbon Arc Cutting with Air equipment, grinders, test meters and gauging devices.
Repair Austenitic Manganese steel castings (Frogs) for welding by performing correct procedures according to current industry standards, and welding repair manuals.
Identify metallurgical effects that take place in Austenitic Manganese steel as the steel is heated and cooled.
Select correct current when operating welding machines (power supplies), i.e., Constant Current (CC) or Constant Voltage (CV).
Select the approved electrode type, size, and parameters for the process being used for the repair of Austenitic Manganese steel.
Perform maintenance and repairs on Austenitic Manganese steel rail road frog castings and related equipment according to the welding repair manual with selected welding and cutting processes.
Demonstrate the ability to successfully contour Austenitic Manganese steel to railroad standards using the approved grinding techniques and gauging tools.
Use the approved Dye Penetration methods to test welded repairs made to the surface of the Austenitic Manganese steel castings before, during, and after welding and grinding is completed.

Content Outline and Competencies:

I. Safety
   A. Follow the correct and approved safety rules and procedures
according to JCCC and BNSF safety sheets.
   B. Use PPE when welding, cutting, grinding, and testing procedures on
rail steel.
   C. Demonstrate correct and safe methods to set up and shut down the
CAC-A cutting process.
   D. Perform accurate cuts using the CAC-A process
   E. Demonstrate safety procedures when operating welding equipment.
   F. Demonstrate proper procedures when operating grinding equipment.
   G. List safety rules for welding and cutting Austenitic Manganese
steel.

II. Identify and locate various controls on equipment related to repairing
Austenitic Manganese steel castings.
   A. Select correct amperage and voltage required for the operation of
welding power supplies.
   B. Use a multi-meter to accurately measure welding voltages and welding
amperage at the welding arc.
   C. Demonstrate the correct method to set up and shut down grinding
equipment.
   D. Perform accurate grinding on Austenitic Manganese steel castings
using appropriate grinding stones to contour rail steel to meet industry
standards.

III. Identify and appropriately select and prepare Austenitic Manganese
steel for welding according to industry standards.
   A. Use current welding repair manual to select correct repair
procedures for Austenitic Manganese steel.
   B. Select SMAW or FCAW process for the correct industry standard for
the repair of Manganese steel castings.
   C. Demonstrate correct methods for the welding repair of Austenitic
Manganese steel.
   D. List current industry standards for the repair of Austenitic
Manganese steel.

IV. Identify metallurgical effects of welds made when repairing Austenitic
Manganese steel frog castings.
   A. Explain the term interpass temperature.
   B. Interpret hardness levels of Austenitic Manganese steel.
   C. List and define metallurgical terms associated with Austenitic
Manganese steel welding.

V. Select correct current when operating SMAW, FCAW power supplies.
   A. Explain the term SMAW as related to Austenitic Manganese steel.
   B. Explain the term FCAW as related to Austenitic Manganese steel.
   C. Demonstrate correct and safe methods to set up and shut down CC and
CV power supplies.
   D. Use a CC power supply to successfully weld Austenitic Manganese
steel frog castings using
the correct SMAW techniques.
   E. Use a CV power supply to successfully weld Austenitic Manganese
steel frog castings using the correct FCAW techniques.
   F. List correct welding procedures for SMAW.
   G. List correct welding procedures for FCAW.

VI. Select the approved electrode for the repair of rail steel.
   A. Identify the correct electrode types for the SMAW process.
   B. Identify the correct electrode type for the FCAW process.
   C. Select the correct parameters (amps) for SMAW electrodes.
   D. Select the correct parameters (volts) for FCAW electrodes.
   E. List factors that determine the type, size and parameters when
selecting electrodes.

VII. Perform maintenance and repairs on Austenitic Manganese steel
according to industry standards.
   A. Use the current welding repair manual to locate correct procedures.
   B. Perform minor maintenance on welding equipment, i.e, power supplies,
cables, electrode holders, wire feed units and wire feed guns, (CAC-A)
equipment.
   C. List steps and/or methods used to make minor repairs to equipment
used to maintain Austenitic Manganese steel.

VIII. Demonstrate the correct technique to contour radius and straight
edging on Austenitic Manganese
steel frog castings.
   A. Select appropriate grinding equipment when working on a Austenitic
Manganese steel railroad frog casting.
   B. Perform grinding procedures according to current welding manual.
   C. List correct gauging tools required to check contour and straight
edging of Austenitic Manganese steel Frogs.
   D. Use correct technique and approved gauges to verify and confirm
radius and running surface of repaired Austenitic Manganese steel rail
road frog casting.

IX. Perform dye penetration procedures to successfully check welded
railroad frogs for surface
defects.
   A. Select approved dye penetrant solution.
   B. Apply dye penetrant in a safe and correct manner.
   C. Inspect Austenitic Manganese steel frog surface for flaws or
defects.
   D. List steps to successfully perform the dye penetrant test on
Austenitic Manganese steel frogs.

Method of Evaluation and Competencies:

Lab competencies will be assigned a level of competency of 0-10, 10
being high.

Demonstrate by achieving 100% on a safety test.

Demonstrate by achieving a minimum of 80% each on two tests.

Participation                     10% of grade
Classroom and Lab competencies    50% of grade
Mid-term exam                     10% of grade
Written final exam                30% of grade
TOTAL                            100%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A.72-5207). Safety glasses must meet American National Standards Institute Z87.1 specifications. Note: Most prescription eyewear does not meet ANSI Z87.1. Students who wear prescription glasses must: 1) provide evidence that existing eyewear meets ANSI Z87.1, or 2) wear cover goggles (if allowable), or 3) purchase and wear ANSI Z87.1 prescription eyewear.

Student Responsibilites:

Disabilities:

RRIT 160

Title: Mechanical Basic Welding*
Number: RRIT-160
Effective Term: Spring 2013
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Course Fees:

All fees paid for approved BNSF employees.

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the shielded metal arc welding (SMAW) process.
Demonstrate the oxy-propane cutting (OPC) or oxyfuel cutting (OFC) process.
Demonstrate the plasma arc cutting (PAC) and plasma arc gouging processes.
Demonstrate the air carbon arc cutting (CAC-A) process.
Demonstrate the ability to weld selected lab projects.
Demonstrate the ability to set up, weld and test v-groove welds.
Demonstrate the ability to visually inspect welds in accordance with the AWS D15.1 code.
Pass an AWS D15.1 code test.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. Oxyfuel Cutting
  A. Demonstrate the set up and breakdown of oxyfuel cutting equipment.
  B. Demonstrate straight cuts on steel plate.

III. Plasma Arc Cutting and Gouging
  A. Demonstrate the setup and breakdown of plasma arc cutting and gouging equipment.
  B. Demonstrate straight cuts on steel plate.
  C. Gouge the backing strips off the 1 1/2" test coupons.

IV. Air Carbon Arc Cutting
  A. Demonstrate the set up and breakdown of air carbon arc cutting equipment.
  B. Remove 1/4" backing plate from the single-v-groove test plate.
V. SMAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.

VI. SMAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 groove weld test.

VII. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

VIII. Destructive Inspection of Welds
  A. Perform face and root bends in accordance with AWS D15.1.
  B. Inspect face and root bends in accordance with AWS D15.1.

Method of Evaluation and Competencies:

Lab Competencies 50%
Classroom/Lab Participation 10%
Quizzes 5%
Midterm Test 5%
Final Test 10%
Code Weld Test 20%
TOTAL 100%

Grade Criteria:

A = 95 - 100%
B = 90 - 94%
C = 80 - 89%
D = 70 - 79%
F = 0 - 69%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.

Student Responsibilites:

Disabilities:

RRIT 162

Title: Mechanical Welding Structural Stick*
Number: RRIT-162
Effective Term: Spring 2013
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Course Fees:

All fees paid for approved BNSF employees.

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the ability to weld selected lab projects.
Demonstrate proper weld bead sequencing on multi-pass groove welds using shielded metal arc welding (SMAW).
Demonstrate the shielded metal arc welding (SMAW) process in the horizontal (2G), vertical up (3G), and overhead (4G) positions.
Demonstrate the ability to set up, weld and test v-groove welds in the horizontal (2G), vertical up (3G), and overhead (4G) positions.
Demonstrate the ability to visually inspect welds in accordance with the AWS D15.1 code.
Pass AWS D15.1 test plates for unlimited thickness in the horizontal (2G), vertical up (3G), and overhead (4G) positions.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. SMAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Complete selected quality fillet welds.

III. SMAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 groove weld tests in the horizontal, vertical up, and overhead positions.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform side bends in accordance with AWS D15.1.
  B. Inspect side bends in accordance with AWS D15.1.

Method of Evaluation and Competencies:

Lab Competencies 10%
Classroom/Lab Participation 10%
Midterm Test 5%Final Test 15%
2G Code Test 20%
3G Code Test 20%
4G Code Test 20%
TOTAL 100%

Grade Criteria:
A = 95 - 100%
B = 90 - 94%
C = 80 - 89%
D = 70 - 79%
F = 0 - 69%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.

Student Responsibilites:

Disabilities:

RRIT 164

Title: Mechanical Welding Structural Wire*
Number: RRIT-164
Effective Term: Spring 2013
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Course Fees:

All fees paid for approved BNSF employees.

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the ability to weld selected lab projects.
Demonstrate proper weld bead sequencing on multi-pass groove welds using flux core arc welding (FCAW).
Demonstrate the flux core arc welding (FCAW) process in the horizontal (2G), vertical up (3G), and overhead (4G) positions.
Demonstrate the ability to set up, weld and test v-groove welds in the horizontal (2G), vertical up (3G), and overhead (4G) positions.
Demonstrate the ability to visually inspect welds in accordance with the AWS D15.1 code.
Pass AWS D15.1 test plates for unlimited thickness in the horizontal (2G), vertical up (3G), and overhead (4G) positions.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. FCAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper equipment set up for the FCAW process.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.

III. FCAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper equipment set up for the FCAW process.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 groove weld tests in the horizontal, vertical up, and overhead positions.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform side bends in accordance with AWS D15.1.
  B. Inspect side bends in accordance with AWS D15.1.

Method of Evaluation and Competencies:

Lab Competencies 10%
Classroom/Lab Participation 10%
Midterm Test 5%
Final Test 15%
2G Code Test 20%
3G Code Test 20%
4G Code Test 20%
TOTAL 100%

Grade Criteria:

A = 95 - 100%
B = 90 - 94%
C = 80 - 89%
D = 70 - 79%
F = 0 - 69%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.

Student Responsibilites:

Disabilities:

RRIT 166

Title: Mechanical Welding Air Brake Pipe*
Number: RRIT-166
Effective Term: Spring 2013
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Course Fees:

All fees paid for approved BNSF employees.

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate and describe shop safety.
Demonstrate the ability to weld selected lab projects.
Demonstrate proper welding techniques using shielded metal arc welding and flux core arc welding.
Demonstrate the shielded metal arc welding and flux core arc welding processes on various pipe welds.
Demonstrate the ability to visually inspect welds.
Demonstrate the ability to conduct visual and destructive inspections of welds in accordance with the AWS D15.1 code.
Pass AWS D15.1 pipe tests.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. SMAW and FCAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.

III. SMAW and FCAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode selection.
  D. Demonstrate proper welding techniques.
  E. Complete selected quality groove welds.
  F. Demonstrate correct heat control techniques.
  G. Pass an AWS D15.1 pipe tests.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform face and root bends in accordance with AWS D15.1.
  B. Inspect face and root bends in accordance with AWS D15.1.

Method of Evaluation and Competencies:

Lab Competencies 10%
Classroom/Lab Participation 10%
Midterm Test 5%
Final Test 15%
Pipe Code Tests 60%
TOTAL 100%

Grade Criteria:

A = 95 - 100%
B = 90 - 94%
C = 80 - 89%
D = 70 - 79%
F = 0 - 69%

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.

Student Responsibilites:

Disabilities:

RRIT 168

Title: Mechanical Welding Sheet Metal*
Number: RRIT-168
Effective Term: Spring 2013
Course Type: Career
Credit Hours: 3
Contact Hours: 5
Lecture Hours: 1
Lab Hours: 4

Description:

Prerequisite: Approval of Burlington Northern Santa Fe (BNSF) Training Director

Course Fees:

All fees paid for approved BNSF employees.

Textbooks:

http://bookstore.jccc.edu/

Supplies:

Refer to the instructor's course syllabus for details about any supplies that may be required.

Objectives

Demonstrate shop safety and the safety rules required when using various welding and cutting processes.
Demonstrate the ability to weld selected lab projects.
Demonstrate proper welding techniques required for groove, flare-bevel, and fillet welding sheet metal using the gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW) processes.
Demonstrate the ability to set up, weld and test sheet metal welds.
Demonstrate the ability to visually inspect welds in accordance with the AWS D15.1 code.
Pass AWS D15.1 sheet metal tests.

Content Outline and Competencies:

I. Safety Rules and Procedures
  A. Follow safety rules and procedures at all times.
  B. Demonstrate the appropriate use of personal protective equipment (PPE).
  C. Describe safety hazards associated with cutting and welding.

II. GMAW and GTAW Fillet Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct base metal preparation.
  C. Demonstrate proper electrode and filler metal selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality fillet welds.
  F. Pass an AWS D15.1 sheet metal fillet weld tests.

III. GMAW and GTAW Groove Welds in Selected Positions
  A. Demonstrate proper PPE.
  B. Demonstrate correct sheet metal preparation.
  C. Demonstrate proper electrode and filler metal selection.
  D. Demonstrate proper welding techniques.
  E. Successfully complete selected quality groove and flare-bevel welds.
  F. Pass an AWS D15.1 sheet metal groove and flare-bevel tests.

IV. Visual Inspection of Welds
  A. Identify common visual discontinuities and defects on welds.
  B. Inspect welds for pass/fail ratings according to AWS D15.1 standards.
  C. Use appropriate inspection tools.

V. Destructive Inspection of Welds
  A. Perform sheet metal tests in accordance with AWS D15.1.
  B. Inspect sheet metal tests in accordance with AWS D15.1.

Method of Evaluation and Competencies:

Classroom/Lab Participation 10%
Midterm Test 5%
Final Test 10%
Sheet Metal Code Tests 75%
TOTAL 100%

Grade Criteria:

A = 95 - 100%
B = 90 - 94%
C = 80 - 89%
D = 70 - 79%
F =

Caveats:

Safety Glasses: Safety glasses with side shields are required to be worn during lab activities associated with this course. This is in compliance with accepted eye protection practices and Kansas State Law (K.S.A. 72-5207). Safety glasses must meet American National Standards Institute Z87.1. Students who wear prescription glasses must: a) provide evidence that existing eyewear meets ANSI Z87.1, or b) wear cover goggles (if allowable), or c) purchase and wear ANSI Z87.1 prescription eyewear.
Face Shield and Goggles: When grinding with a hand grinder, BNSF requires that students wear approved face shield and goggles.
Boots: BNSF approved footwear is required.
Welding Helmet: BNSF approved welding helmet is supplied for students.
Welding Gloves and Jacket: BNSF approved welding gloves and jackets are supplied for students.
Ear Plugs: BNSF approved ear plugs are supplied for students.